Adjustable headrest assembly with neck support feature

ABSTRACT

A headrest assembly includes a front surface and a frame member disposed within an interior of the headrest bun. First and second hinge members are coupled to opposite sides of the frame member and first and second side supports are operably coupled to the first and second hinge members, such that the first and second side supports are independently operable between stowed and extended positions relative to the headrest bun. The first and second side supports extended outwardly from the front surface of the headrest bun in the extended position, and the friction hinges are tuned to move the first and second side supports towards the stowed position when the first and second side supports are contacted by a vehicle occupant during a vehicle impact event.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.14/994,587, filed on Jan. 13, 2016, entitled ADJUSTABLE HEADRESTASSEMBLY WITH NECK SUPPORT FEATURE, the entire disclosure of which ishereby incorporated by reference.

FIELD OF THE INVENTION

The present invention generally relates to a headrest assembly for avehicle seat, and more particularly, to a headrest assembly that isadjustable to provide enhanced comfort and neck support to a vehicleoccupant

BACKGROUND OF THE INVENTION

Headrests are often disposed on a seatback of a vehicle seat and can beuncomfortable, particularly when the headrest is not adjustable to suitthe needs of a particular vehicle occupant. For tired passengers, longtrips can leave a vehicle occupant with aches and pains associated withsleeping with their head disposed at an awkward angle. Thus, a headrestassembly is desired that provides adjustable neck support for a vehicleoccupant that is easily deployed and configured to revert to a stowedcondition under particular force thresholds.

SUMMARY OF THE INVENTION

One aspect of the present invention includes a vehicle seat having aseatback that is coupled to a seat portion. A headrest assembly issupported from the seatback and operable between first and secondconfigurations. The headrest assembly includes a headrest bun having alower portion and first and second side supports adjustably coupled tothe headrest bun and operable between stowed and extended positions.

Another aspect of the present invention includes a headrest assemblyhaving an internal frame member and a friction hinge coupled to theinternal frame member at a first portion thereof. A side support iscoupled to a second portion of the friction hinge, such that the sidesupport is pivotally coupled to the headrest bun and operable betweenstowed and extended positions. The side support is configured to movefrom the extended position towards the stowed position when contacted bya vehicle occupant during a vehicle impact event.

Yet another aspect of the present invention includes a headrest assemblyhaving a front surface and a frame member disposed within an interior ofthe headrest bun. First and second hinge members are coupled to oppositesides of the frame member and first and second side supports areoperably coupled to the first and second hinge members, such that thefirst and second side supports are independently operable between stowedand extended positions relative to the headrest bun. The first andsecond side supports extended outwardly from the front surface of theheadrest bun in the extended position, and the friction hinges are tunedto move the first and second side supports towards the stowed positionwhen the first and second side supports are contacted by a vehicleoccupant during a vehicle impact event.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a vehicle seat having a headrestaccording to one embodiment of the present invention;

FIGS. 2A-2B are front perspective views of various headrest assemblies,showing relative movement between first and second configurations;

FIG. 3A is a front perspective view of a headrest assembly in a firstconfiguration;

FIG. 3B is a front perspective view of the headrest assembly of FIG. 3Ain a second configuration;

FIG. 4A is a front perspective view of a headrest assembly in a firstconfiguration;

FIG. 4B is a front perspective view of the headrest assembly of FIG. 4Ain a second configuration;

FIG. 5 is a perspective view of a hinge member, showing relative motionof first and second portions of the hinge member;

FIG. 6 is a perspective view of the hinge member of FIG. 5 with thesecond portion exploded away therefrom;

FIG. 7 is a perspective view of the hinge member of FIG. 5 with thefirst portion coupled to a frame member and the second portion coupledto a structural member;

FIG. 8A is a front perspective view of the headrest assembly of FIG. 3Ashowing first and second hinge members coupled to the headrest bun andthe first and second side supports; and

FIG. 8B is a front perspective view of the headrest assembly of FIG. 3Bshowing pivot axes for the first and second hinge members of FIG. 8A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the invention as oriented in FIG. 1. However, itis to be understood that the invention may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

Referring now to FIG. 1, the reference numeral 10 generally designates avehicle seat assembly as illustrated in accordance with an embodiment ofthe present invention. The vehicle seat 10 may be a driver's seat, orany other passenger seat, such as a first row seat, a second row seat orany subsequent row seat. The vehicle seat 10 includes a seat portion 12with a cushion member 12A for supporting a vehicle occupant thereupon. Atrack assembly 13 is coupled to the seat portion 12 and contemplated tobe secured to a floor surface of a vehicle for moving the vehicle seat10 between fore and aft positions. The vehicle seat 10 also includes aseatback 14 extending upwardly from a rear portion of the seat portion12 for supporting a torso of the vehicle occupant. The seatback 14includes an upper portion 16 having a headrest assembly 20 adjustablymounted thereto. The headrest assembly 20 is supported by first andsecond support struts 22, 24 slideably received in the seatback 14 atthe upper portion 16 thereof. The first and second support struts 22, 24are configured to adjustably move the headrest assembly 20 in asubstantially vertical direction as indicated by arrow 25. In use, theseatback 14 is configured to supporting a head of a vehicle occupantwhen the vehicle occupant rests his or her head against the headrestassembly 20. Although an individual vehicle seat 10 is illustrated inthe embodiment of FIG. 1, it is contemplated that any size vehicle seat10 may be utilized, such as a bench seat, which may include one or moreheadrest assemblies.

As further shown in FIG. 1, the headrest assembly 20 includes acentrally disposed headrest bun 26 having a lower mounting portion 28.Disposed below the headrest bun 26, an adjustable neck support feature30 is shown having first and second side portions 32, 34 interconnectedby a middle portion 36 to define a generally U-shaped structure. Thefirst and second side portions 32, 34 are coupled to opposed sides 28A,28B of the lower mounting portion 28 of the headrest bun 26. The firstand second side portions 32, 34 are adjustably coupled to the headrestbun 26 at the lower mounting portion 28, such that the neck supportfeature 30 is operable between stowed and deployed positions S, D in apivoting manner, as further described below. Thus, the headrest assembly20 is contemplated to be a multi-configurational headrest assembly whichis shown in FIG. 1 in a ground state or neutral configuration, whereinthe neck support feature 30 is in the stowed position S. With the necksupport assembly 30 in the stowed position S, a first configuration C1of the headrest assembly 20 is defined. Conversion of the headrestassembly 20 from the first configuration C1 to a second configuration C2providing enhanced neck support, will now be described with reference toFIGS. 2A-2B.

Referring now to FIGS. 2A and 2B, the headrest assembly 20 is shown inthe second configuration C2 which is an enhanced support configurationwith the neck support feature 30 pivoted outwardly to provide a cradledefining a head receiving area 40 for receiving the head of a passenger.As shown in the first configuration C1 of FIG. 1, the headrest assembly20 provides for a generally uniform front facing contour with the necksupport feature 30 positioned in a stowed configuration S relative tothe headrest bun 26, such that the neck support feature 30 and theheadrest bun 26 reside in a substantially common plane. Comparatively,as shown in FIGS. 2A and 2B, the neck support feature 30 is shown in alaterally extended position E, relative to the stowed position S shownin FIG. 1. In the extended position E, the neck support feature 30 hasrotated or pivoted relative to the headrest bun 26 in a substantiallycar-forward and rotational direction as indicated by arrow 42 tolaterally displace the neck support feature 30 relative to the headrestbun 26 to define second configuration C2. As moved to the extendedposition E, the neck support feature 30 is configured to provide supportfor a neck of a vehicle occupant, while the headrest bun 26 providessupport for the back of a vehicle occupant's head. This is due to thestepped or shoulder relationship of the neck support feature 30 and theheadrest bun 26 shown in FIGS. 2A and 2B. It is contemplated that theheadrest bun 26 is a stationary member that does not move as theheadrest assembly 20 adjusts between first and second configurations C1,C2. The neck support feature 30 is contemplated to be coupled to theheadrest bun at pivot locations P1, P2 at first and second side portions32, 34 for rotation about pivot axis PA as shown in FIG. 2B.

Referring now to FIGS. 3A and 3B, another embodiment of the headrestassembly 20A is shown in the first and second configurations C1, C2,respectively. In the first configuration C1, the headrest assembly 20Ais shown having the neck support feature 30 in the stowed position S.The neck support feature 30 includes first and second side supports 32,34 which are disposed on opposite sides 28A, 28B of the lower portion 28of the headrest bun 26. In the stowed position S, the first and secondside supports 32, 34 are disposed in a generally common plane (CP)defined by a front surface 27 of the headrest bun 26. The first andsecond side supports 32, 34 are configured to pivot or rotate outwardlyfrom the stowed position S to the extended position E as shown in FIG.3B along the path as indicated by arrows 44, 46, respectively. In theextended position E, the first and second side supports 32, 34 areconfigured to provide enhanced neck support for a vehicle occupant. Inthe embodiment shown in FIGS. 3A and 3B, the neck support feature 30does not include an interconnecting member, such as middle portion 36shown above with reference to FIGS. 1-2B. In the embodiment shown inFIGS. 3A and 3B, the neck support feature 30 includes separatelyarticulating side support portions 32, 34 which can independently bemoved between the stowed and extended positions as shown in FIGS. 3A and3B, respectively. In the extended position E, the first and second sidesupports 32, 34 are disposed on opposite sides of a head receiving area40. The neck support features of the present concept are contemplated toinclude friction hinges which are coupled to the side supports or sideparts of the neck support feature 30.

Referring now to FIGS. 4A and 4B, another embodiment of the headrestassembly 20B is shown in the first and second configurations C1, C2,respectively. In the first configuration C1, the headrest assembly 20Bis shown having the neck support feature 30 in the stowed position S.The neck support feature 30 includes first and second side supports 32,34 which are disposed around the lower portion 28 of the headrest bun26. The first and second side supports 32, 34 are configured to pivot orrotate outwardly from the stowed position S to the extended position Eas shown in FIG. 4B along the rotational path as indicated by arrow 42.In the extended position E, the first and second side supports 32, 34are configured to provide enhanced neck support for a vehicle occupanthaving moved forward in the direction as indicated by arrow 46. In theembodiment shown in FIGS. 4A and 4B, the neck support feature 30includes side support portions 32, 34 which can be independentlyarticulating side support portions 32, 34, or which can be operablycoupled to one another at seam 48 to be moved between the stowed andextended positions S, E, as shown in FIGS. 4A and 4B, in a simultaneousmanner. The friction hinges used with the present concept will now bedescribed with reference to FIGS. 5 and 6.

Referring now to FIG. 5, a hinge member 50 is shown having a firstportion 52 and a second portion 54 that are configured to rotaterelative to each other. The relative rotation of the first portion 52and the second portion 54 is generally inhibited by internal resistanceof the hinge member 50, which ultimately allows the side supportportions 32, 34 of the neck support feature 30 to be pivoted to theextended position E (FIG. 3B), and further to be retained in theextended position E. Thus, the hinge member 50 is contemplated to be afriction hinge, wherein the side support portions 32, 34 can rotate toany intermediate position disposed between the stowed position S (FIG.3A) and the extended position E (FIG. 3B) and retain placement in suchan intermediate position by the internal resistance of the frictionhinge 50. Thus, the example hinge member 50 shown in FIG. 5 is used topivotally couple the side portions 32, 34 of the neck support feature 30to a portion of an internal frame (M as shown in FIGS. 7 and 8A)disposed within an interior of the headrest assembly 20. Hinge member 50may be akin to a friction hinge used on a laptop computer to pivotallymove a display screen to various positions and further retaining thescreen in a desired position relative to a keyboard.

With further reference to FIG. 5, the first portion 52 and the secondportion 54 are operably coupled to a hinge pin 60 having first andsecond sides 62, 64. The hinge pin 60 includes an outer surface 66disposed over a generally cylindrical body portion 68. The first portion52 of the hinge member 50 is shown in the embodiment of FIG. 5 as havinga mounting portion 70 with mounting apertures 72, 74 disposedtherethrough. First and second mounting arms 76, 78 extend outwardlyfrom the mounting portion 70 for coupling the first portion 52 of thehinge member 50 to the first side 62 of the hinge pin 60. Similarly, thesecond portion 54 of the hinge member 50 is shown in the embodiment ofFIG. 5 as having a mounting portion 80 with mounting apertures 82, 84disposed therethrough. First and second mounting arms 86, 88 extendoutwardly from the mounting portion 80 for coupling the second portion54 of the hinge member 50 to the second side 64 of the hinge pin 60.Thus, as shown in FIG. 5, the first and second portions 52, 54 of thehinge member 50 are configured to pivot on the hinge pin 60 along therotational paths indicated by arrows 90, 92 along a pivot axis PA whichis defined by the hinge pin 60.

Referring now to FIG. 6, the hinge member 50 is shown having the secondportion 54 exploded away from the hinge pin 60. In this view, first andsecond receiving apertures 100, 104 of the second portion 54 can be seenas disposed through the first and second mounting arms 86, 88. The firstand second receiving apertures 100, 104 are configured to receive thehinge pin 60 in a frictional engagement as shown in FIG. 5. The firstand second receiving apertures 100, 104 include interior engagementsurfaces 102, 106, respectively, which are configured to engage theouter or exterior surface 66 of the hinge pin 60 to cause internalinterference therebetween. Points of internal interference are shown inFIG. 6 at points I in the engagement of first portion 52 of the hingemember 50 and the first side 62 of the hinge pin 60. Thus, it iscontemplated that the first portion 52 of the hinge member 50 includessimilar receiving apertures as described above with reference to secondportion 54.

It is contemplated that the internal interference between the first andsecond portions 52, 54 and the hinge pin 60 can be tuned to accommodatespecific applications. For use in conjunction with the present concept,it is contemplated that the internal interference is in a range ofapproximately 50-200 N to ensure that the first and second side members32, 34 will retract towards the stowed position S from the extendedposition E (or any intermediary position therebetween) during an impactevent, wherein the head of a vehicle occupant may contact the first andsecond side members 32, 34 in a sudden manner. Such an impact event mayinclude a rear-end collision event, wherein a vehicle occupant's headmay suddenly contact the first and second side members 32, 34 of theheadrest assembly 20 at a force sufficient to move the first and secondside members 32, 34 towards the stowed position S. Such a force may beabout 800-1000 N acting on the first and second side members 32, 34.Thus, with an internal interference in a range of approximately about50-200 N, and more preferable about 70-100 N, the first and second sidemembers 32, 34 will easily retract when impacted by a vehicle occupantduring a collision event, but will have enough static force to remain inthe deployed position for support as determined by the user. Thisgenerally equates to a static friction of about 100 N to get the firstand second side members 32, 34 moving, and a required force of about 70N to get the first and second side members 32, 34 once the first andsecond side members 32, 34 have started moving. Thus, a torque range forthe first and second side members 32, 34 is about 8.0 Newton-Meters toabout 60.0 Newton-Meters.

Referring now to FIG. 7, the first portion 52 and the second portion 54of the hinge member 50 are shown operably coupled to the hinge pin 60 atfirst and second sides 62, 64, respectively. The first portion 52 isshown coupled to a frame member M via fasteners 110 as coupled tomounting apertures 72, 74 of the mounting portion 70 of the firstportion 52. The frame member M is contemplated to be disposed within aninterior of the headrest bun 26, as best shown below in FIG. 8A. Thesecond portion 54 of the hinge member 50 is shown coupled to astructural member SM via the engagement of fasteners 110 with themounting apertures 82, 84 of the mounting portion 80 of the secondportion 54 of the hinge member 50. The structural member SM iscontemplated to be disposed within an interior of one of the first andsecond side members 32, 34 to which the hinge member 50 is coupled. Thestructural member SM may be a plastic part that is flexible, and mayinclude a foam covering for providing a cushioned effect to the firstand second side supports 32, 34. The structural member SM may also be arigid member disposed within the side supports 32, 34. The frame memberM is contemplated to be a rigid member disposed within the headrest bun26 of the headrest assembly 20. It is further contemplated that thefirst portion 52 of hinge member 50 may be fixedly coupled to the hingepin 60, such that the second portion 54 of the hinge member 50 may bethe only portion that rotates on the hinge pin 60 for moving theassociated side member of the headrest assembly 20.

Referring now to FIG. 8A, the frame member M is shown disposed within aninterior of the headrest bun 26 of the headrest assembly 20A. FIG. 8Aincludes a headrest assembly 20A akin to the headrest assembly 20Adescribed above with reference to FIG. 3A. First and second hingemembers 50A, 50B are shown coupled to the frame member M at oppositeends thereof, and further coupled to first and second structural membersSM1, SM2 which are disposed in the first and second side supports 32, 34for pivoting movement thereof. Thus, as shown in FIG. 8B, the first andsecond hinge members 50A, 50B (FIG. 8A) are disposed along verticalpivoting axis is PA1, PA2 for movement of the first and second sidemembers 32, 34 to the extended positions E along the paths as indicatedby arrows 44 and 46. Horizontal pivoting axes are also contemplated foruse with the present concept, as shown, for example, in the embodimentof FIGS. 2A and 2B.

The friction hinge(s) used with the present concept may be similar tothe SBI88 series hinges supplied by TorqMaster International ofStamford, Conn. One skilled in the art will appreciate, given thebenefit of this disclosure, the application-specific requirements willdirect the appropriate selection and implementation of the frictionhinge(s), or any other suitable device, having the necessary internalresistance necessary to carry out the spirit of the invention.

Further, the relative movement and positioning of the side supportmembers 32, 34 and may also be influenced by one or more otherstructures, such as a series of detents, springs, locks, “question mark”bands, reel clips, friction disks, nylon wraps and the like thatprovided various levels of internal interference of the hinge member 50and restrain the first and second side support members 32, 34 in theextended position E, the stowed position S, or any intermediate positiontherebetween. The friction hinges are configured to retain the first andsecond side supports in the stowed position, the extended position andany intermediary position therebetween when rotated thereto and withoutoutside forces acting on the first and second side supports.

It will be understood by one having ordinary skill in the art thatconstruction of the described invention and other components is notlimited to any specific material. Other exemplary embodiments of theinvention disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the invention as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present invention. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present invention, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims unless these claims by their language expressly stateotherwise.

What is claimed is:
 1. A vehicle seat, comprising: a seatback coupled toa seat portion; a headrest assembly supported from the seatback andoperable between first and second configurations, wherein the headrestassembly includes: a headrest bun having an interior; a frame memberdisposed within the interior of the headrest bun; first and second sidesupports adjustably coupled to the frame member, wherein the first andsecond side supports are each operable between stowed and extendedpositions; a first hinge member having a first portion coupled to afirst side of a first hinge pin and a second portion coupled to a secondside of the first hinge pin that is positioned below the first side ofthe first hinge pin, wherein the first portion of the first hinge memberis fully disposed within the interior of the headrest assembly andfixedly coupled to the frame member, and further wherein the secondportion of the first hinge member is disposed outside of the interior ofthe headrest bun and coupled to a first structural member disposedwithin an interior of the first side support; and a second hinge memberhaving a first portion coupled to a first side of a second hinge pin anda second portion coupled to a second side of the second hinge pin thatis positioned below the first side of the second hinge pin, wherein thefirst portion of the second hinge member is disposed within the interiorof the headrest assembly and fixedly coupled to the frame member, andfurther wherein the second portion of the second hinge member isdisposed outside of the interior of the headrest bun and coupled to asecond structural member disposed within an interior of the second sidesupport.
 2. The vehicle seat of claim 1, wherein the first and secondside supports are pivotally coupled to the frame member.
 3. The vehicleseat of claim 2, wherein the first and second side supports extendoutwardly in a forward direction from the headrest bun in the extendedposition.
 4. The vehicle seat of claim 3, wherein the first and secondside supports are disposed in a generally common plane defined by afront surface of the headrest bun when the first and second sidesupports are in the stowed position.
 5. The vehicle seat of claim 4,wherein the first and second side supports are disposed on oppositesides of a head receiving area when the first and second side supportsare in the extended position.
 6. The vehicle seat of claim 1, whereinthe first and second hinge members are friction hinges having aninternal resistance of the first and second portions to the hinge pin ina range of about 50 N to about 200 N.
 7. The vehicle seat of claim 6,wherein the first and second hinge members define substantially verticalpivot axes for pivoting movement of the first and second side supports.8. The vehicle seat of claim 1, wherein the headrest assembly issupported on the seatback by first and second support struts that arevertically adjustable.